Composite grid with tack film for asphaltic paving, method of paving, and process for making a composite grid with tack film for asphaltic paving

Abstract

A composite material comprises: an open grid comprising at least two sets of strands. Each set of strands has openings between adjacent strands. The sets are oriented at a substantial angle to one another. A tack film is laminated to the open grid. The tack film has first and second major surfaces, such that a material of the tack film at its first and second major surfaces includes about 50% or more of resinous non-asphaltic component and about 50% or less of asphaltic component.

1. A composite material, comprising:
 an open grid comprising at least two sets of strands, each set of strands having openings between adjacent strands and the sets being oriented at as substantial angle to one another; and 
 a continuous polymer extrusion tack film sheet laminated to the open grid to cover the openings of the grid, the tack film having first and second major surfaces, such that a material of the tack film at the first and second major surfaces thereof is a resinous non-asphaltic material, the tack film comprising a carrier layer surrounded by a single layer of the resinous non-asphaltic material. 
 
     
     
       2. The material of  claim 1 , wherein the material at the surface of the tack film is of a type that is activated at a paying temperature, pressure, or both, to form a bond compatible with asphaltic paving, said coating not being tacky at a temperature of about 20° C. and a pressure of about one atmosphere. 
     
     
       3. The material of  claim 1 , wherein the tack film comprises a carrier substrate coated with the resinous non-asphaltic material, the carrier substrate formed of at least one of the group consisting of polyethylene, polypropylene, polyethylene and polypropylene copolymer, polyvinyl chloride, polyamide, acrylic, polyester, thermo plastic polyolefin and ethylene vinyl acetate. 
     
     
       4. The material of  claim 1 , wherein the resinous non-asphaltic material comprises at least one of the group consisting of polyvinyl chloride, acrylic, polyethylene, polyamide, polypropylene, and ethylene vinyl acetate. 
     
     
       5. The material of  claim 4 , wherein the resinous non-asphaltic material comprises a polyvinyl chloride acrylic latex material. 
     
     
       6. The material of  claim 5 , wherein the tack film comprises a carrier substrate coated with the polyvinyl chloride acrylic latex material, the carrier substrate formed of at least one of the group consisting of polyethylene, polypropylene, polyethylene and polypropylene copolymer, polyvinyl chloride, polyamide, acrylic, polyester, thermo plastic polyolefin and ethylene vinyl acetate. 
     
     
       7. The material of  claim 1 , wherein the material of the tack film at the first and second major surfaces thereof further comprises about 1-8 wt. % wax release agent. 
     
     
       8. The material of  claim 1 , wherein the material of the tack film at the first and second major surfaces thereof further comprises about 1-8 wt. % wax release agent, and one or more of the group consisting of soluble polymer, ammonia, thickener, colorant, defoamer, and plasticizer. 
     
     
       9. The material of  claim 1 , wherein:
 the carrier substrate is formed of at least one of the group consisting of polyethylene, polypropylene, polyethylene and polypropylene copolymer, polyvinyl chloride, polyamide, acrylic, polyester, thermo plastic polyolefin and ethylene vinyl acetate; and 
 the resinous non-asphaltic material, based upon the weight of dry ingredients, comprises: 
 40-60 wt % PVC-acrylic latex; 
 5-25 wt % styrene-acrylic acid latex; and 
 5-25 wt % ethylene-acrylic acid latex; 
 the resinous non-asphaltic material further comprising internally plasticized PVC latex, organic oil/silica defoamer, carbon black dispersion, EBS anti-blocking wax dispersion: acrylic solution polymer, non-ionic surfactant, fluorosurfactant; and polyacrylic acid thickener. 
 
     
     
       10. The material of  claim 1 , wherein the grid further comprises a binder resin coating disposed around said strands and the binder resin coating does not close the openings between the adjacent strands, and
 the continuous tack film sheet is distinct from the non-asphaltic coating of the open grid. 
 
     
     
       11. The material of  claim 10 , wherein the binder resin coating is formed of said resinous non-asphaltic coating. 
     
     
       12. The material of  claim 10 , wherein the binder resin coating at least partially impregnates the strands. 
     
     
       13. The material of  claim 1 , wherein, the strands comprise E-glass filaments. 
     
     
       14. The material of  claim 1 , wherein the material further comprises a second tack film laminated to a face of the open grid opposite the first tack film, the second tack film having first and second major surfaces, such that a material of the second tack film at the first and second major surfaces thereof is a resinous non-asphaltic material. 
     
     
       15. The composite material of  claim 1 , wherein the resinous non-asphaltic material comprises:
 45-50 wt % pvc-acrylic latex; 
 7-14 wt % internally plasticized pvc latex; 
 15-20 wt % styrene-acrylic acid latex; 
 12-18 wt % ethylene-acrylic acid latex; 
 0.1-0.3 wt % organic oil/silica defoamer; 
 0.5-2 wt % carbon black dispersion; 
 1-3 wt % EBS anti-blocking wax dispersion; 
 1.5-3.5 wt % acrylic solution polymer; 
 0.05-0.15 wt % non-ionic surfactant; 
 0.05-0.15 wt % fluorosurfactant; 
 0.25-1.0 wt % polyacrylic acid thickener. 
 
     
     
       16. A paving structure comprising:
 a binder layer of asphaltic paving material 
 a layer of a composite material laid over the binder layer, comprising: 
 an open grid comprising at least two sets of strands, each set of strands having openings between adjacent strands and the sets being oriented at a substantial angle to one another, and 
 a continuous polymer extrusion tack film sheet laminated to the open grid to cover the openings of the grid, the tack film having first and second major surfaces, such that a material of the tack film at the first and second major surfaces thereof is a resinous non-asphaltic material, the tack film comprising a carrier layer surrounded by a single layer of the resinous non-asphaltic material; and 
 a surface layer of asphaltic material above the composite material. 
 
     
     
       17. The paving structure of  claim 16 , wherein the material of the tack film at the first and second major surfaces thereof comprises a polyvinyl chloride acrylic latex material. 
     
     
       18. The paving structure of  claim 16 , wherein the tack film comprises a carrier substrate coated with the polyvinyl chloride acrylic latex material, the carrier substrate formed of at least one of the group consisting of polyethylene, polypropylene, polyethylene and polypropylene copolymer, polyvinyl chloride, polyamide, acrylic, polyester, thermo plastic polyolefin and ethylene vinyl acetate. 
     
     
       19. The paving structure of  claim 16 , wherein the composite material further comprises a second tack film laminated to a face of the open grid opposite the first tack film, the second tack film having first and second major surfaces, such that a material of the second tack film at the first and second major surfaces thereof is a resinous non-asphaltic material. 
     
     
       20. The composite material of  claim 16 , wherein the resinous non-asphaltic material comprises:
 45-50 wt % pvc-acrylic latex; 
 7-14 wt % internally plasticized pvc latex; 
 15-20 wt % styrene-acrylic acid latex; 
 12-18 wt % ethylene-acrylic acid latex; 
 0.1-0.3 wt % organic oil/silica defoamer; 
 0.5-2 wt % carbon black dispersion; 
 1-3 wt % EBS anti-blocking wax dispersion; 
 1.5-3.5 wt % acrylic solution polymer; 
 0.05-0.15 wt % non-ionic surfactant; 
 0.05-0.15 wt % fluorosurfactant; and 
 0.25-1.0 wt % polyacrylic acid thickener. 
 
     
     
       21. A prefabricated composite material, comprising:
 an open grid comprising at least two sets of glass strands, each set of strands having openings between adjacent strands and the sets being oriented at a substantial angle to one another, the grid having a binder resin coating disposed around the strands and at least partially impregnating the strands, such that the binder resin coating does not close the openings between the adjacent strands, and 
 a continuous polymer co-extrusion tack film sheet laminated to the open grid to cover the openings of the grid, the continuous polymer co-extrusion tack film sheet being distinct from the binder resin coating of the open grid, the tack film having first and second major surfaces, such that a material of the tack film at the first and second major surfaces thereof is a resinous non-asphaltic material, the tack film co-extrusion having a carrier film surrounded by a single layer of the resinous non-asphaltic material, 
 wherein the composite material including the open grid and the tack film is a prefabricated material in the form of a spiral roll. 
 
     
     
       22. The composite material of  claim 1 , wherein the open grid and tack film make up a prefabricated material arranged in a spiral roll.